Flashlight



March 23, 1965 A. H. MOORE FLASHLIGHT 2 Sheets-Sheet l Filed Sept. 20, 1962 (IZG 2 (22 FIG. 1

l (ze Ilu/2O INVENTOR Ar'rhur H. Moore A. H. MOORE FLASHLIGHT March 23, 1965 2 Sheets-Sheet 2 Filed Sept. 2O 1962 FIG. 5

INVENTOR.

Arthur H. Moore United States Patent C) 3,175,080 FLASHLIGHT Arthur Holroyd Moore, Fairfield, Conn., assigner to The Bridgeport Metal Goods Mfg. Co., Bridgeport, Conn., a corporation of Connecticut Filed Sept. 2t?, 1962, Ser. No. 225,045 7 Claims. (Cl. 24d-10.65)

This invention relates generally to flashlights and particularly to a flashlight having certain new and improved features including switch, battery mounting and reilector arrangements.

In accordance with the invention, I have devised a flashlight casing consisting essentially of two rectangular mating halves which may be held securely together by a single centrally located attaching stud. The shape of the casing is such that it readily tits the hand of the user and may be carried conveniently when not in use in pocket or purse. Within the casing, two batteries are located in side-by-side relation and are series connected to the flashlight bulb by a switch, contact strips and through a spring having substantially parallel, interconnected coils. The casing parts may be molded of plastic to provide members integral therewith for locating 'and holding the batteries, contact strips, etc.

A further aspect of the invention resides in a toggle switch arrangement for making and breaking the electrical circuit contact between the llashlight bulb and the batteries. A further feature involves the construction of the reflector unit which, though of generally rectangular shape, includes means for projecting a flashlight beam having a generally circular outline.

In the following description reference is made, by way of a non-limiting example, to one form of construction of a flashlight devised in accordance with the invention and illustrated in the accompanying drawings in which:

FIG. l is a cross-sectional View showing the llashlght casing and the general arrangement of the several internal parts of the flashlight;

FIG. 2 is a view taken in the direction of arrows 2 2 of FIG. 1;

FIG. 3 is a detailed illustration, somewhat enlarged, showing the construction of the toggle switch used in the illustrated embodiment of the invention;

FIG. 4 illustrates the mounting arrangement of the double coiled base spring for series connecting the batteries in side-by-side relationship;

FIGS. 5 and 6 are perspective and end views respectively of the flashlight reflector; and

FIG. 7 is an exploded perspective view of the flashlight casing.

Referring now to the drawing, the new flashlight 10 comprises 4an outer shell or casing formed in two tlat generally rectangular mating halves 11 and 12. As shown, the casing parts readily lend themselves to being molded of a plastic material which are interitted along the contacting edges thereof by means of scarf joints 13, 13 (FIG. 4). As best seen in FIG. 2, each of the casing parts 11 and 12 is molded internally to have opposed cylindrical stud receiving projections 14, 14' deilning aligned bores 16, 16 therein for the reception of a stud 17. The latter when inserted within the bores 16, 16 is adapted to be threaded into a cap nut 18 in order to draw the halves of the casing 11 and 12 securely together.

Secured to the casings 11 and 12 are grips or inserts 15, held thereto by the central stud 17 (see FIGS. 2 and 7). The inserts are preferably knurled on the outer surfaces thereof and are advantageously of a color different from that of the casings 11 and 12 for decorative effect. The inserts 15, 15 accentuate the pistol-grip shape of the ilashlight which permits the latter to lit readily into the palm of the users hand.

At their upper ends, each of the casing parts 11 and 12, define an inwardly inclined outer lip 12a, 11a and immediately below the lip, a shoulder 19. The lip and shoulder form a groove 20 which receives correspondingly formed edge portions of a reflector assembly comprising a reflector body 21 and an outer transparent sheet 22 of glass or plastic. It will be understood that the reflector body 21 may be molded of a clear plastic, for example, which has been given a coating of light rellecting material upon the inner or concave surface thereof. Furthermore, as seen in FIGS. 1, 5 and 6, the reflecting portions of the body 21 include two opposed generally cylindrical end Walls 23, 24 and intermediate these, two longer reilecting walls 27, 28 of considerably less curvature. The walls 27, 28 each include a semi-circular series of striations 27', 28 arranged parallel to the `axis of the light beam. These striations tend to diffuse the light reflected from the flattened Walls, 27, 28. The overall result is a tendency for the beam or light to be circular in outline notwithstanding the generally rectangular shape of the reflector body.

Joined to the interior of the reflector body 21 is a metallic sleeve 30 having a shoulder 36a which abuts beneath the edge of a central opening 21 in the reflector body. The upper edge 30b of the sleeve 30 is rolled over the interior edge of the adjacent sides of the opening 21 in order to secure the sleeve 30 firmly to the body 21. The interior of the shoulder 30a forms an abutment surface for a mounting flange 31 of a conventional flashlight bulb 32 such that when the flange 31 is ,against the shoulder 30a the incandescent portions of the bulb 32 extend within the relector body 21 as illustrated. The sleeve 30 is further formed having threaded convolutions 30e such that a correspondingly threaded retainer 33 may be threaded within the sleeve 30 to hold the bulb flange 31 against the interior of the sleeve shoulder 30a. The retainer 33 dellnes a bore 33 permitting the metal shank of the bulb 32 and the base terminal 34 thereof to extend from the retainer.

Beneath the bulb 32 are two flashlight batteries 36 and 37 arranged in generally side-by-side relation within the casing parts 11 and 12. Each of the parts 11 and 12 is formed, in addition to the central cylindrical projections 14, 14', to have transverse partitions 38, 38 and 39, 39. The lower set of partitions, viz. 39, 39', each includes a central rectangular pin 4t) for separating the batteries 36 and 37 nearest the lower ends thereof, while the ends of the batteries nearest the bulb 32 are separated by the projections 14, 14. The terminal button 36a of battery 36 makes contact with an electrical contact strip 41 having an end portion 41a retained within a slotted post 42. The opposite end 41b of the strip 41 is adapted to contact the terminal button 34 of the bulb 32. The battery 36 is held resiliently between the strip 41 which is formed to have a leaf spring eect and a helically wound section 44a of a spring 44 which is supported by the base of the casings 11 and 12. The spring 44 intermediate the helical section 44a and a second helically wound section 441: extends and is retained within a slot defined by two prongs 45 and 46 which are molded transversely of the base of the casing part 11. The battery 37 is retained between the spring section 44b and a second Contact strip 47 which is rigidly secured within a slotted post 48 formed integrally with the casing part 11.

As seen in FIG. 2, the upper end of the strip 47 is bifurcated and defines a generally semi-circular cut-out 49. The cut-out 49 is adapted to receive the cylindrical stem of a contact button 50 whose function is to bridge the gap between the strip 47 and the sleeve 30, the latter being in electrical Contact with the flange 31 of the bulb. The flange 31 comprises conventionally, a rst terminal arranco contact for the bulb filament, while the button 3d is a second lterminal contact of the filament. Thus, when the button Sil is in the position shown in FIG. 1, an electrical circuit is established through the bulb 32 by means of an electrical circuit from the terminal 31 through the sleeve 30, the button 50, the strip 47, batteries 36 and 37 including the intermediate spring contact 44, the Contact strip 41 and therefrom, to the second terminal 34 of the bulb. When the button Sti is in the -dotted-line position of FIG. 1, the electrical circuit is broken.

The button 50 forms the terminal end of a toggle switch indicated generally Jby the reference numeral 51. The switch S1 comprises an outer, semi-circular actuating portion 52 constructed of molded plastic which, as best seen in FiG. 3, is attached by means of a pivot pin 53 to the body of the casing l1. internally of the member 52, the button i) is formed as a plunger having a radially enlar ed portion Sila which is permitted to have limited axial vmovement within a cylindrical bore 52a. A spring 54 is located within the bore 52a tending to urge the button Sil outwardly thereof. The spring actuation of the button is sufficient at all times to assure positive electrical contact between the button 50 and the sleeve Sil. As will be observed by the dottedline position in FIG. 1, the electrical connection from the batteries to the bulb 32 will be broken when the toggle switch S1 is rotated clockwise to sever contact between the button Sil and the contact strip 47.

It will be apparent from the foregoing description that the new flashlight possesses certain significant advantages. These include the compact shape of the flashlight which readily 'fits itself to the hand of the user and lends itself to easy carrying in pocket or purse. Further advantages are seen in the arrangement and construction of the several parts of the flashlight, including the toggle switch, and the inexpensive manner in which the outer casing parts 11 and 12 may be molded to provide internally, positive placement and holding of the batteries, contact strips, etc. lt will be understood, however, that the foregoing specific description relates only to a particular embodiment and is therefore merely representative. Therefore, in order fully to understand the spirit and scope of the invention, reference should be made to the appended claims in which:

I claim:

1. A flashlight comprising a molded casing constructed in two flat generally rectangular mating halves having joining side wall and end wall portions defining at one end a generally rectangular opening for the reception of a reflector and bulb assembly, each of said casings being molded internally to have opposed contacting projections defining aligned bores internally thereof receiving a threaded stud, said stud comprising the sole fastening means for securing said casings together, each of said casings further defining integrally molded internal supporting means for positive longitudinal alignment of two flashlight batteries in side-by-side relation, the upper ends of said batteries being separated by said opposed projections, a spring having substantially parallel helically coiled sections attached to the end wall of one of said casings and arranged to support the lower ends of said batteries, said spring forming an electrical connection between said batteries connected in series, contact strips connecting the upper ends of said batteries respectively to a first terminal of said bulb and to a movable switch contact adapted to make connection with a second terminal of said bulb, and means formed integrally with said casing for securely holding each of said contact strips.

2. A flashlight comprising a molded casing constructed in two fiat generally rectangular mating halves having joining side wall and end wall portions defining at one end a generally rectangular opening for the reception of a reflector and bulb assembly, each of said casings being molded internally to have opposed contacting projections delining aligned bores internally thereof receiving a threaded stud; said stud comprising the sole fastening means for securing said casings together, each of said casings further defining integrally molded internal supporting means for positive longitudinal alignment of two flashlight batteries in a side-by-side relation, the upper ends of said batteries being separated by said opposed projections, a spring having substantially parallel helically coiled sections attached to the end wall of one of said casings and arranged to support the lower ends of said batteries, said spring forming an electrical connection between said batteries connected in series, contact strips connecting the upper ends of said batteries respectively to a first terminal of said bulb and to a movable switch Contact adapted to make connection with a second terminal of said bulb, said Contact strip cooperating with said switch comprising a bifurcated member defining a cut-out, said switch comprising a rotatable button including a cylindrical stem portion adapted for reception in said cut-out thereby to make contact with said bifurcated contact strip, means pivotally mounting said button to a portion of the casing, means externally of the casing permitting manual rotation of said button toward and away from the Contact strip, means connecting said button to the second of the bulb terminals when said button is in contact with said bifurcated strip, and means formed intgrally with said casing for securely holding each of said contact strips.

3. A flashlight comprising a molded casing constructed in two fiat generally rectangular mating halves having joining side wall and end wall portions defining at one end a generally rectangular opening for the reception of a reflector and bulb assembly, each of said casings being molded internally to have opposed contacting projections defining aligned bores internally thereof receiving a threaded stud; said stud comprising the sole fastening means for securing said casings together, each of said casings further de'ning integrally molded internal supporting means for positive longitudinal alignment of two flashlight 'batteries in side-by-side relation, the upper ends of said batteries being separated by said opposed projections, a spring having substantially parallel helically coiled sections attached to the end wall of one of said casings and arranged to support the lower ends of said batteries, said spring forming an electrical connection Vbetween said batteries connected in series, contact strips connecting the upper ends of said batteries respectively to a first terminal of said bulb and to a movable switch contact adapted to make connection with a second terminal of said bulb, means formed integrally with said casing for securely holding each of said contact strips and a reflector assembly mounted within said rectangular opening including a reflector body having generally arcuate shortened end walls corresponding generally to the end wall portions of the casings and having longer Walls of less curvature intermediate said end walls comprising in the internal reflecting surface portions thereof a series of longitudinal striations, said striations tending to diffuse light reflected from the elongate side Walls and tending to project therefrom together with the arcuate end Walls a beam having a generally circular outline.

4. ln combination with a iiashlight casing containing a pair of batteries connected in series, a bulb and means for establishing electrical circuit through said bulb and batteries, the improvement wherein said electrical circuit includes a first contact strip connecting one of said batteries to a first terminal of said bulb and a second contact strip connected at one end to said second battery and being bifurcated at its other end to define a cut-out, and a movable switch having a rotatable contact button with a conducting stem portion adapted for reception in said cut-out to thereby make contact with said second contact strip, means pivotally mounting said button to a portion of the casing, means extending externally of the casing for permitting manual rotation of said button toward U and away from the second contacts strip, and means connecting said button to a second terminal the said bulb when said button is in contact with said second Contact strip to complete said electrical circuit.

5. A flashlight comprising a molded casing constructed in two generally mating halves having joining side wall and end wall portions deuing at one end a generally rectangularopening having curved sides for the reception of a reflector and bulb assembly, each of said casing halves being molded internally to have opposed projections dening aligned bores internally thereof receiving a threaded stud; said stud comprising the sole fastening means for securing said casings together, each of said casing halves further defining integrally molded internal supporting means for longitudinal alignment of two tiashlight batteries in side-by-side relation, the upper ends of said batteries being separated by said opposed projections, spring rneans having substantially parallel helically coiled sections attached to the end wall of one of said casing halves and arranged to support the lower ends of said batteries, said spring means forming an electrical connection between said batteries connected in series, a first contact strip connecting the upper end of one of said batteries to a tirst terminal ot said bulb and a second contact strip connecting the upper end of the other of said batteries to a movable switch adapted to selectively connect said other battery through said second Contact strip with a second terminal of said bulb, means formed integrally with said casing for securely holding each of said contact strips, and a reflector assembly mounted within said rectangular opening and including a reflector body having generally arcuate shortened end walls corresponding generally to the end wall portions of the casings and having longer walls of less curvature intermediate said end walls comprising in the internal reflecting surface thereof a series of longitudinal striations, said striations tending to dilluse light reliected from the elongated side Walls and together with said arcuate end walls tending to project a beam having a generally circular outline.

6. A flashlight comprising a molded casing constructed in two generally mating halves having joining side wall and end wall portions defining at one end a generally rectangular opening having curved sides for the recep tion of a deliector and bulb assembly, each of said casing halves being molded internally to have opposed projections detining aligned bores internally thereof receiving a threaded stud; said stud comprising the sole fastening means for securing said casings together, each of said casing halves further defining integrally molded internal supporting means 'for longitudinal alignment of ltwo flashlight batteries in side-by-side relation, the upper ends of said batteries being separated by said opposed projections, spring means having substantially parallel helically coiled sections attached to the end wall of one or said casing halves and arranged to support the lower ends of said batteries, said spring means forming an electrical connection between said batteries connected in series, a iirst contact strip connecting the upper end of one of said batteries to a irst terminal of said bulb and a second contact strip connecting the upper end of the other of said batteries to a movable switch adapted to selectively connect said other battery through said second contact strip with a second terminal of said bulb, means formed integrally with said casing for securely holding each of said Contact strips and a reliector assembly mounted within said rectangular opening and including a reliector body having a center spaced inwardly of said opening through which said bulb extends, an arcuate smooth reflecting surface extending in opposite directions from said center to the curved end walls of said opening and in a direction at right angles thereto to deline arcuate edges spaced inwardly of the curved side walls `of said opening along a direction perpendicular to the plane of said opening, and reflector side walls having diffused rellecting surfaces thereon extending in a direction perpendicular to the plane of said opening and connecting said arcuate edges to the curved side walls of said opening.

7. The combination set forth in claim 6 wherein said diffused reiiecting surfaces comprise a series of striations extending parallel to said beam of light.

References Cited bythe Examiner UNITED STATES PATENTS 1,299,397 4/ 19 Conklin et al.

1,624,436 4/27 Rosernier 21m-41.35 X 1,737,027 11/29 schoonmaker 24U-41.36 2,211,258 8/40 Delfel 240-4135 X 2,272,040 2/42 Muldoon 240--1065 2,489,806 11/49 Sliver 24m-10.66 2,690,503 9/54 Garland 24U- 10.66 2,843,730 7/58 Schwartz 24U-40.65

NORTON ANSI-1ER, Primary Examiner. 

1. A FLASHLIGHT COMPRISING A MOLDED CASING CONSTRUCTED IN TWO FLAT GENERALLY RECTANGULAR MATING HALVES HAVING JOINING SIDE WALL AND END WALL PORTIONS DEFINING AT ONE END A GENERALLY RECTANGULAR OPENING FOR THE RECEPTION OF A REFLECTOR AND BULB ASSEMBLY, EACH OF SAID CASINGS BEING MOLDED INTERNALLY TO HAVE OPPOSED CONTACTING PROJECTIONS DEFINING ALIGNED BORES INTERNALLY THEREOF RECEIVING A THREADED STUD, SAID STUD COMPRISING THE SOLE FASTENING MEANS FOR SECURING SAID CASINGS TOGETHER, EACH OF SAID CASINGS FURTHER DEFINING INTEGRALLY MOLDED INTERNAL SUPPORTING MEANS FOR POSITIVE LONGITUDINAL ALIGNMENT OF TWO FLASHLIGHT BATTERIES IN SIDE-BY-SIDE RELATION, THE UPPER ENDS OF SAID BATTERIES BEING SEPARATED BY SAID OPPOSED PROJECTIONS, A SPRING HAVING SUBSTANTIALLY PARALLEL HELICALLY COILED SECTIONS ATTACHED TO THE END WALL OF ONE OF SAID CASINGS AND ARRANGED TO SUPPORT THE LOWER ENDS OF SAID BATTERIES, SAID SPRING FORMING AN ELECTRICAL CONNECTION BETWEEN SAID BATTERIES CONNECTED IN SERIES, CONTACT STRIPS CONNECTING THE UPPER ENDS OF SAID BATTERIES RESPECTIVELY TO A FIRST TERMINAL OF SAID BULB AND TO A MOVABLE SWITCH CONTACT ADAPTED TO MAKE CONNECTION WITH A SECOND TERMINAL OF SAID BULB, AND MEANS FORMED INTEGRALLY WITH SAID CASING FOR SECURELY HOLDING EACH OF SAID CONTACT STRIPS. 